Apparatus for making tufted fabrics

ABSTRACT

The apparatus includes cooperating tufting needles, pile formers and latch needles for forming pile tufts on a backing fabric while positioning small locking threads through lower bight portions on the tufts being formed to secure them to the backing fabric. To permit the use of less pile yarn for obtaining any given height of pile on the upper face of the backing fabric, the tufting yarns are under relatively high tension so that they are drawn upwardly relative to the backing fabric and so that portions of the locking threads passing through the lower bight portions are displaced upwardly into the backing fabric. Also, novel means are provided for guiding the locking threads into the hooks of the latch needles each time they enter through the tuft lower bight portions so that the latch needles will draw corresponding stitches of lockin thread through the respective lower bight portions.

United States Patent Maclsaac, Jr. et al.

[ 51 July 18,1972

APPARATUS FOR MAKING TUFI'ED FABRICS [72] Inventors: John I. Maclsuc,Jr.; James 13. buy,

both of Eden, N.C.

[73] Assignee: Fleldcrest Mills, Inc., Eden, NC.

[22] Filed: Jan. 29, 1971 [211 App]. No.: 110,851

[52] US. Cl ..1l2/79 R, 66/85 A [51] Int. Cl ..D05c 15/22 [58]FieldofSearch ..112/79 R, 79A, 80, 266,410; 66/85 A [56] ReferencesCited UNITED STATES PATENTS 1,827,614 10/1931 Riviere ..l l2/266 X3,253,426 5/1966 Mauersbcrger... 1 12/79 R 3,361,096 H1968 Watkins 12/79R4n 3,421,929 l/l969 Watkins 1 12/79 R 3,428,007 2/1969 Wignall et al...1 12/79 R all FOREIGN PATENTS OR APPLICATIONS 813,439 5/1959 GreatBritain ..ll2/79R 821,702 10/1959 Great Britain Primary Examiner-JamesR. Boler Attorney-Parrott, Bell, Seltzer, Park 8: Gibson [57] ABSTRACTThe apparatus includes cooperating tutting needles, pile formers andlatch needles for forming pile tufts on a backing fabric whilepositioning small locking threads through lower bight portions on thetufts being fonned to secure them to the backing fabric. To permit theuse of less pile yarn for obtaining any given height of pile on theupper face of the backing fabric, the tufiing yarns are under relativelyhigh tension so that they are drawn upwardly relative to the backingfabric and so that portions of the locking threads passing through thelower bight portions are displaced upwardly into the backing fabric.Also, novel means are provided for guiding the locking threads into thehooks of the latch needles each time they enter through the tuft lowerbight portions so that the latch needles will draw correspondingstitches of lockin thread through the respective lower bight portions.

10 Claims, 18 Drawing Figures Patented July 18, 1972 3,677,206

8 Sheets-Sheet l H 2 247 lo y a V 5 2H; fly-1 22 (O"-1 60) 2.3g?

2|; alar 22 fly-2 INVENTORS:

JOHN T MAcIsAAc, (T2,. and JAMES E. TROY MMQ/%, 4

ATTORNEYS Patented July 18, 1972 3,677,206

8 Sheets-Sheet l uvvavmes ATTORNEYS Patented July 18, 1972 3,677,206

8 Sheets-Sheet 5 INVENTORS.

36m '1'. MACI$AAC,J'2.. and JAMES E: TROY ATTORNEYS Patented July 18,1972 3,677,206

8 Sheets-Sheet 4 Q mvsmons:

JOHN T. MAcIsAAcJz.

ATTORNEYS Patented July 18, 1972 3,677,206

8 Sheets-Sheet 5 g 146 65a 7 ,s PAT TEEN 67 85a De-vmcr: 45 4 5! 52 5CREEL. 5 o u AND R TENSDN R1 MEANS 57 l/VVEA/ r025: Jim: "I? MACISAAQIE.

andJ'AMEs E. TROY ATTORNEYS Patented July 18, 1972 3,677,206

8 Sheets-Sheet 6 T I26 1Z7 INVENTORS:

TOHNTMACISAACJR and Jams ETRQY ATTORNEYS I22 IZI 8 Sheets-Sheet 8Patented July 18, 1972 APPARATUS roa MAKING rump FABRICS This inventionrelates to an improved apparatus for making tufted pile fabrics, and isparticularly devised for making fabrics of the type disclosed in ourcopending application Ser. No. 110,967 filed concurrently herewith andentitled 'IUFIED PILE FABRICS AND METHOD OF MAKING SAME.

In most conventional tufting machines, tuf'ting needles insert pileyarns downwardly through a backing fabric in which pile loops are formedby loopers which enter the loops below the backing fabric and hold thema predetermined distance below the back of the fabric as the tuftingneedles subsequently withdraw upwardly from the backing fabric. Theloopers subsequently withdraw from the loops as the backing fabric isadvanced so that a portion of each pile yarn is positioned upon theupper, back face, of the backing fabric as the needles are again loweredto form a succeeding transverse row of tufts.

Such conventional tufling machines have many drawbacks in thatconsiderable pile yarn is wasted on the back face or non-pile face ofthe fabric, and the loops or tufis are easily pulled out of the backingfabric even after a back sizing material has been applied thereto. Also,when variable-length pile tufts have been formed, it has beenpractically impossible to obtain a distinct line of demarcation betweentufis of one height and tufts of a different height because of inherentvariances in the particular type of robbing technique employed.

It is an object of this invention to provide an improved apparatus formaking tufted pile fabrics permitting use of less pile yarn forobtaining any given height of pile while firmly securing the pile tuftsto the backing fabric, facilitating a higher rate of production than hasbeen obtainable on conventional tufting machines heretofore, and whereina clear line of demarcation may be obtained between adjacent tufts ofdifferent heights or lengths when variable-height tufts are desired inthe pile fabric.

Another object of the invention is to provide an apparatus for makingtufted pile fabrics wherein the lower bight portions of pile yarns,inserted through a backing fabric by tutting needles, are secured to thebacking fabric by moving complementary latch needles into the lowerbight portions being presented by the tufting needles, and utilizingmeans for guiding a locking thread, preferably of substantially smallersize than the pile yarns, through the hook of each latch needle. Thehooks of the latch needles, with the locking thread therein, are thenwithdrawn from the respective pile yarn lower bight portions, so as todraw a loop locking thread through each lower bight portion.

Some of the objects and advantages of the invention having been stated,other objects will appear as the description proceeds, when taken inconnection with the accompanying drawings, in which FIG. 1 is afragmentary vertical sectional view through the tuft-forminginstrumentalities of the apparatus of this invention showing a tuftingneedle, a latch needle and a locking thread guide at the start of acycle in an operation thereof;

FIGS. 2-7 are similar to FIG. 1, but showing successive stages in anoperating cycle of the needles and the locking yarn guide;

FIG. 8 is a fragmentary plan view taken substantially along line 8-8 inFIG. 1;

FIG. 9 is a fragmentary plan view taken substantially line 9-9 in FIG.7;

FIG. 10 is a front elevation of a tufting machine embodying theinvention with parts broken away;

FIG. 11 is a side elevation looking at the right-hand side of thetufting machine of FIG. 10;

FIG. 12 is a fragmentary vertical sectional view taken substantiallyalong line 12-12 in FIG. 10;

FIG. 13 is a side elevation of the tufling machine looking at theleft-hand side of FIG. 10;

FIG. 14 is an enlarged fragmentary elevation, partially in section,taken substantially along line 14-14 in FIG. 10,

along showing mechanism for imparting lateral shifting or shoggingmovement to the pile formers;

FIG. 15 is a fragmentary rear elevation looking at the Mthand side ofFIG. 14 and also looking at the opposite side of the mechanism forimparting lateral movement to the pile formers from that shown in FIG.10;

FIGS. 16 and 17 are enlarged fragmentary vertical sectional views takensubstantially along the respective lines 16-16 and 17-17 in FIG. 10; and

FIG. 18 is a detail of mechanism for imparting lateral and verticalreciprocating motions to the locking thread guides, taken substantiallyalong line 18-18 in FIG. 1 7.

Referring more specifically to the drawings and especially to FIGS. [-9,the tufling machine embodying the apparatus of the instant inventioncomprises tuft-forming instrumentalities including a row of plaintufting needles 20, a row of complementary latch needles 21, respectivemovable locking thread guides 22, and a row of pile formers 23, all ofwhich rows extend laterally of the path of travel of a suitable backingfabric 24. The backing fabric may be of woven or knitted constructionand is shown in the form of a woven fabric formed from weft yarns 24ainterwoven with warp yarns 24b and denoting respective transverse andlongitudinal directions of the backing fabric 24.

Conveniently, and by way of example, the backing fabric is shown asbeing advanced in a substantially horizontal path of travel over asupport means or bed plate 25 and past the tuftforminginstrumentalities, with the pile formers 23 being positioned above thebacking fabric, the tufiing needles 20 penetrating the backing fabricfrom above the same, and with the latch needles 21 and correspondinglocking thread guides 22 positioned below the backing fabric 24. It isto be understood, however, that the backing fabric 24 may be advancedthrough the machine at an incline or in a vertical direction, ifdesired, with corresponding changes being made in the location andattitude of the tuft-forming instrumentalities, without departing fromthe invention. As is usual, the front portion of bed plate 25 issuitably slotted to accommodate passage of tufting needles 20therethrough while supporting the backing fabric adjacent the needles20.

A tensioned tufting yarn or pile yarn 26 extends downwardly through theeye of each tufting needle 20, and the eye of each thread guide 22 has aseparate stitching or locking thread 27 extending upwardly therethrough.The locking threads 27 are under relatively lighter effective tensionthan pile yarns 26 and preferably are of a translucent syntheticmaterial of substantially smaller size than the pile yarns 26 so as tobe barely visible and present very little projection along the lowerface of backing fabric 24.

Each latch 21 may be of a type generally used on circular knittingmachines and comprises a shank 21a having a downwardly facing hook 2lbon its free rear end adapted to be engaged and thus closed by a latch21c pivotally suspended from shank 21a. In those instances in which thepile yarn tufts are to be of only one height, it is apparent that all ofthe pile formers may be of the same effective height. As shown, however,the pile former 23 of FIGS. 1-7 includes two loop-forming stages orsurfaces 23a, 23b of difl'erent effective heights selectively movableinto and out of the tuft-forming zone or the plane of the verticallyreciprocatory tufting needle 20.

A description of the operation of the tuft-forming instrumentalitieswill now be given, and the mechanism for supporting and operating thetuft-forming instrumentalities will be later described. According to theinvention, each of the pile yarns 26 successively formed into alongitudinal row of pile loops or loop pile tufts 26:: on the upper faceof backing fabric 24 as the tufting needles 20 successively penetratebacking fabric 24 and insert the pile yams through the backing fabric toform lower bight portions 26b on the loops.

As each successive lower bight portion 26b is inserted through thebacking fabric, latch needles 21 cooperate with locking thread guides 22to position locking threads 27 alongside the lower face of the backingfabric and through the successive lower bight portions to secure theloops to the backing fabric. Additionally, each successive lower bightportion 26b of pile yarn 26 is displaced upwardly by drawing the pileyarns upwardly relative to the backing fabric so that portions of thelocking threads passing through the corresponding lower bight portionsare displaced upwardly into the backing fabric.

The operation of the tuft-forming instrumentalities in forming tufts inthe aforementioned manner will now be described with respect to thesingle set of instrumentalities shown in FIGS. 1-7 illustratingsuccessive stages in one complete 360 cycle thereof. At the start or-360 position (FIG. I) it is to be assumed that tufling needle occupiesits uppermost position above the plane of pile former 23, that astufting needle 20 starts downwardly, the last previously formed lowerbight portion 26b of pile yarn 26 and a loop 27a of locking thread 27are looped beneath shank 21a of latch needle 21, and that the lockingthread 27 extends rearwardly from the second last previously formed tuftlower bight portion 26b through the then open hook 21b of the latchneedle, and through the eye of the corresponding thread guide 22 to thesource, as further illusu'ated in FIG. 8. It should be noted that,whenever tufting needle 20 occupies its uppermost or 0-360 position,latch needle 21 will have completed a rearward stroke thereof to thebroken-line position and will be in the course of a forward strokethereof from right to left in FIG. 1.

FIG. 2 shows the position of the tuft-forming instrumentalities at about45 in a cycle thereof in which pile former 23 has started a lateralshifting movement toward the observer, and latch needle 2] has withdrawnforwardly from the previously formed pile yarn lower bight portion 26b,pulling a succeeding loop 270 of locking thread 27 through the latterlower bight portion 261:. In FIG. 3, at about 60 in a cycle, pile former23 has moved toward the observer sufficiently so that tufting needie 20has started to move past the far side of pile former 23, thus loopingpile yarn 26 across and above pile former 23.

With further downward movement of tufting needle 20, latch needle 26withdraws from and casts off the previous locking thread loop 270 whiledrawing the succeeding locking thread loop through the previous loop 27aas in the successive 60, I20" and 180 positions of FIGS. 3, 4 and 5.Thus, by the time tufting needle 20 reaches its lowermost position as inFIG. 5, and due to the relatively high tension being applied to pileyarn 26, tufting needle 29 will have pulled the last preceding lowerbight portion 26b upwardly into backing fabric 24 so that the entirecorresponding lower bight portion is positioned above the upper face ofbacking fabric 24 or at least the upper surface of the lower bightportion is positioned above the plane of the lower face of backingfabric 24.

At the same time, the latter lower bight portion 26d aided in liftingthe last locking thread loop 270 to be cast off of the latch needle andthis, coupled with the tension being applied to the correspondinglocking thread 27, causes the locking thread loop to be drawn upwardlyagainst the lower face of backing fabric 24 to complete a stitch thereofwhile the portions of the locking thread passing through thecorresponding lower bight portion are displaced upwardly into thebacking fabric. It should be noted from the foregoing description that aportion of each locking thread 27 extending from a previously formedtuft lower bight portion 26b is looped around one leg of a nextsucceeding lower bight portion and then drawn through the latter bightportion and through a previously formed loop portion 270 of the samelocking thread, also extending from the said previously formed lowerbight portion, so as to form a stitch interconnecting the previouslyformed and next succeeding tuft lower bight portions 26b. Also, thetension means associated with pile yarns 26, and which will be laterdescribed, serves not only to maintain tension in the pile yarns butalso serves to prevent slackening of the pile yarns during reciprocationof the tufting needles 20 so that the tufting needles will retract thepreviously formed lower bight portions of the pile yams into the backingfabric as the tufting needles penetrate the backing fabric and pull thepile yarns over adjacent pile formers while the tufting needles formsucceeding lower bight portions adjacent the lower face of the backingfabric.

Afler the last locking thread loop 27a and the last lower bight portion26b have been released as in FIG. 3, latch needle 21 starts a rearwardstroke to the right from the position of FIG. 4 before tufting needle 20reaches its lowermost position of FIG. 5. Thus, at about the 210position in a cycle, latch needle 2l enters the new lower bight portion26b of pile yarn 26, between one leg thereof and one side of tuftingneedle 20, as tufting needle 20 is moving upwardly as indicated in FIG.6. While the latch needle 21 is moving rearwardly through the new lowerbight portion 26b and through the new locking thread loop 27a, theseloops swing the latch 21c to open the hook 21b as needles 20, 21 returnto the 0-360 position of FIG. 1.

While latch needle 21 is moving rearwardly, however, the correspondingthread guide 22 is moving downwardly and also laterally toward theobserver so that, at about the 285 position of a cycle (FIG. 7), thethread guide 22 becomes positioned below and adjacent the opposite sideof the longitudinal plane of latch needle 21 from that in which it waspreviously positioned, as shown in FIG. 9. With further rearwardmovement of latch needle 20, the locking thread guide 22 then movesupwardly and away from the observer so that by the time latch needle 21has reached its rear-most position, such as that indicated in brokenlines in FIG. I, the locking thread 27 is again inserted through thehook 21b of the latch needle 21 so as to be positioned as in FIGS. 1 and8.

A repeat cycle of tufting needles 20, latch needles 21 and pile yarnguides 22 is then effected in the manner heretofore described with theexception that pile formers 23 move from right to left or away from theobserver in FIGS. 1-7 so that pile yarns 26 are again looped over thecorresponding stages of pile formers 23 but in the opposite directionfrom that in which they were looped during the immediately precedingcycle of needles 20, 21 and locking thread guides 22. In other words,during alternate cycles of needles 20, 21 and guides 22, pile formers 23move laterally in one direction, and during intervening cycles ofneedles 20, 21 and guides 22, pile formers 23 move laterally in theopposite direction.

Since pile formers 23 move laterally relative to needles 20, 21 andbacking fabric 24, it follows that tufting needles 20 successivelyinsert each pile yarn at substantially longitudinally aligned points inthe advancing backing fabric 24 such that the lower bight portions 26bof each longitudinal row of loops 260 also are positioned in acorresponding row. Thus, a common locking thread 27 is positionedthrough the successive lower bight portions of each longitudinal rowthereof.

Afier the loops 26a are formed, some or all of them may be severed toform substantially U-shaped tufts therefrom. The severing of the loopsmay be effected by use of conventional shearing apparatus and/or eitheror both of the loop-forming stages 23a, 23b of each of certain pileformers 23 or of all of the pile formers may be provided with suitableupwardly projecting cutter blades (not shown) on the free forward endsthereof. If a cutter blade is provided on a relatively low loopforrningstage 230 of any particular pile former 23, the cutter blade may projectabove stage 230 such a distance as to sever the low loops 26a only, orthe blade may be of such height as to sever both the low loops and thehigh loops.

The tufting machine will now be described more in detail. Referring toFIGS. ll and 13, it will be observed that backing fabric 24 is drawnupwardly from a suitable supply roll 30 journalled on opposing compositeside frame members 31a, 31b of a frame broadly designated at 31. Fromsupply roll 30, backing fabric 24 passes over, under and over respectivesuccessive guide or tension rolls 32, 33, 34 (FIGS. 16 and 17) and thenpasses forwardly in a substantially horizontal path of travel over thefabric supporting means or bed plate 25 and through the tuft-forminginstrumentalities. Bed plate 25 is carried by a transverse beam 31c offrame 31. From bed plate 25, backing fabric 24 passes forwardly beneathand partially around a first take-up roll 35, then over a second take-uproll 36, then downwardly and beneath an idler roll 37 (FIGS. 11 and 13),and thence forwardly to a suitable cloth roll-up or take-up means, notshown.

Take-up rolls 35, 36 are joumalled in laterally spaced brackets 31d, 31:(FIGS. 10, 11 and 13) secured to front portions of side frame members310 and 31b. Intenneshing gears 35a, 35b are provided on correspondingends of the shafts of take-up rolls 35, 36. The take-up rolls may bedriven by an electric motor 40 (FIGS. and 11) carried by frame member310 and connected by belt and pulley means 41, 42 to a main drive shafi43 journalled in frame members 31a, 31b and extending through an upperhousing portion 31f of frame 31. Belt and pulley means 44 also connectmain drive shaft 43 to the input side of a gear box 45 whose output sidehas the shaft of first take-up roll 35 connected thereto, thus, drivingthe take-up rolls at a speed proportional to that of the rate ofrotation of main drive shaft 43. Fabric tension roll 32 is joumalled inframe 31 and has a suitable braking device 46 (FIG. 13) thereon tomaintain backing fabric 24 under predetermined tension as it is beingadvanced forwardly through the tuftforming instrumentalities.

The pile yarns 26 pass forwardly from a suitable source 50, such as acreel (FIG. 11), and over suitable rods 51, 52 between which individualweight members 53 are suspended on the pile yarns to maintain them underpredetermined relatively high tension while preventing the occurrence ofany slack therein. From rod 52, pile yarns 26 pass forwardly, thendownwardly through suitable successively arranged pile yarn guide means55, 56, 57 and thence through the eyes of the respective tufting needles(FIG. 16). The two lower pile yarn guide means 56, 57 are mounted forsubstantially vertical reciprocation with tufting needle 20, and theupper pile yarn guide means 55 is carried by frame 31.

As shown in FIG. 16, the upper portions of tufting needles 20 aresuitably removably secured in a transverse needle supporting bar 60suitably secured to the lower ends of a pair of substantially verticallydisposed guide posts 61 supported for vertical movement in housingportion 31] of frame 31. The upper end of each post 61 is pivotallyconnected, by means of a link 62 (FIG. 16), to a corresponding crank arm63 suitably secured to a tufting needle motion rocker shaft 64journalled in housing portion 31f of frame 31. For oscillating needlemotion crank shaft 64 to impart substantially vertical reciprocation totufting needles 20, it will be observed in FIG. 12 that one end portionof rocker shaft 64 has another crank 65 fixed thereon.

One end of a cam-connecting arm 66 is pivotally and adjustablyconnected, as at 660, to crank 65. The pivot 66a is adjustable along aslot 650 provided in the crank 65. The other end of connecting arm 66 ismounted on an eccentric cam 67 fixed on main drive shafi 43. Thus,rotation of main drive shaft 43 and its cam 67 transmits substantiallyvertical reciprocation to tufting needles 20 through the interveningconnections heretofore described.

The front portions of latch needles 2] are suitably secured in a commontransverse latch needle support bar 70 positioned closely beneath thepath of travel of backing fabric 24 and suitably secured to a pluralityof transversely spaced guide blocks 71, only one of which is shown inFIGS. 16 and 17. Each guide block 71 is mounted for forward and rearwardsliding movement on a guide rod 72 whose forward portion is suitablysecured to a corresponding bracket 73. As shown in FIG. 10, brackets 73extend downwardly and are suitably secured to a transverse frame member31 extending between and suitably secured to side frame members 31a,31b. The upper end of a crank arm 75 is pivotally connected to eachguide block 71 (FIGS. 16 and 17). The lower ends of crank arms 75 aremounted on a common transverse shaft 76 journalled on side frame members31a, 31b (FIG. 10).

A latch needle rocker shaft 80 (FIGS. 16 and 17) is journalled in sideframe members 31a, 31b rearwardly of crank arms 75. Cranks B1 are fixedon and depend from rocker shaft 80 and are connected by respective links82 to medial portions of the respective crank arms 75. As shown in FIG.12, latch needle rocker shaft has at least one crank 85 fixed thereonand extending upwardly therefrom to which the lower portion of acam-connecting arm 86 is pivotally and adjustably connected, as at 86a.The upper portion of cam-connecting am 86 is loosely mounted on aneccentric cam 87 suitably secured to main drive shafi 43. Crank 85preferably is provided with an elongate adjustment slot 85a therein foradjustably receiving the pivot 86a of connecting arm 86 so as to permitadjusting the length of stroke of the latch needles. Thus, rotation ofshafi 43 transmits forward and rearward reciprocatory motion to latchneedles 21 through the intervening connections heretofore described.

As heretofore described, locking thread guides 22 should move bothlaterally and substantially vertically so as to position locking threads27 in the hooks of respective latch needles 21. Accordingly, lockingthread guides 22 are carried by a transverse bar 90 (FIGS. 16, 17 and18). A depending arm 91 supports each end of bar 90 and the lowerportion of each arm 91 is suitably secured to a pair of tubular guidemembers 92 mounted for lateral, substantially horizontal, slidingmovement on a respective pair of guide rods 93. Guide rods 93 arecarried by a bracket 94 having a substantially vertical guide rod 95extending downwardly therefrom and mounted for su bstantially verticalsliding movement in a guide block 96 suitably secured to thecorresponding side frame member of frame 31 (FIGS. 17 and 18). The lowerend portion of each guide rod 95 has the front end of a correspondinglever 97 pivotally connected thereto. The front ends of levers 97 arepivotally mounted on support brackets 100 suitably secured to thecorresponding side frame members 31a, 31b (FIG. 10).

As best shown in FIGS. 10 and 17, the upper end of a link 101 ispivotally connected to a medial portion of each lever 97. The lower endof each link 101 is pivotally connected to a forward portion of acorresponding cam follower lever 102 pivotally mounted, intennediate itsends, on the corresponding side frame member of frame 31. The rearportion of each cam follower lever 102 has a follower 103 thereonengaging the irregular groove of a corresponding face cam 104. Face cams104 are mounted on a cam shaft 105 (FIGS. 10 and 13) journalled on sideframe members 31a, 31b. Cam shaft 105 is driven by belt and pulley means106 drivingly connecting main driveshaft 43 to cam shaft 105. It is thusseen that face cams 104 transmit substantially vertical motion tosupporting brackets 94 (FIGS. 17 and 18) and thus to locking threadguides 22, through the intervening connections therewith heretoforedescribed, and in timed relation to reciprocation of tufiing needles 20and latch needles 21.

In order to transmit lateral motion to locking thread guides 22, it willbe observed in FIGS. 17 and 18 that the inner end of a link 110 ispivotally connected to one of the depending arms 91 of thread guidesupporting bar 90. The outer end of link 110 is pivotally connected tothe upper end of a follower lever 1 11 (FIGS. 10 and 18) which extendsdownwardly and is pivotally mounted intermediate its ends, as at 112, onside frame member 31b. The lower portion of follower lever 111 has afollower 113 thereon engaging a peripheral groove of irregularconfiguration in a cam wheel 114 fixed on cam shaft 105. It is thus seenthat rotation of cam wheel 114 imparts lateral reciprocatory motion tolocking thread guides 22 through the intervening connections heretoforedescribed.

The locking threads 27 are directed to and through the eyes of lockingthread guides 22 from a suitable source independent of supply and aremaintained under predetermined relatively light tension as compared tothe tension in the pile yarns 26. Accordingly, it will be observed inFIG. 13 that the source of the locking threads 27 is shown, by way ofexample, in the form of a plurality of spools 22a arranged in atransverse row adjacent the rear portion of the machine and looselymounted on corresponding stobs 22b. The stobs 22b are mounted on acommon transverse frame member 31!: adjacent the rear lower portion offrame 31 and project upwardly through a friction material 22c, such asnatural or synthetic rubber, on which the spools rest in frictionalengagement therewith.

Each spool has a weight member 22d resting thereupon which, coupled withthe weight of the respective spool and the thread thereon determines theamount of frictional resistance to rotation applied to the spools by thefriction material 22c, thus determining the amount of tension in threads27. The tension means embodied in the friction material 22c and theweight members 22d is shown by way of example only, it being understoodthat any suitable tension means may be provided for applying tension tothe locking threads 27.

In their course to the lockingthread guides 22, it will be observed inFIG. 17 that the locking threads pass through a pair of spacedtransversely extending guide bars 22 between which drop wires 22f aresuspended on the locking threads, such drop wires being adapted to dropinto engagement with a pair of electrode bars 22 to establish a circuittherebetween and interrupt the circuit to the electric motor 40 tothereby stop the machine in the event of the parting of any one or moreof the locking threads 27 between the source of supply and the lockingthread guides 22.

As heretofore described, pile formers 23 are shifted a relatively shortdistance laterally in one direction during alternate cycles in theoperation of needles 20, 2] and guides 22, and pile formers 23 areshifted laterally in the opposite direction during intervening cycles inthe operation of the needles 20, 21 and thread guides 22. Accordingly,pile formers 23, which are shown in a form of elongate, relatively thinpile wires, are mounted for longitudinal or forward and rearward slidingmovement in a common pile former support bar 120 spaced closely abovethe path of travel of backing fabric 24 and over bed plate 25. Supportbar 120 overlies and serves as a stripper for the backing fabric 24during upward strokes of tufting needles 20. Each end portion of supportbar 120 is suitably secured to a laterally movable bracket 121 supportedfor such movement on a pair of guide rods 122 (FIGS. l4, l5, l6, and 17)suitably secured to a corresponding stationary bracket 123.

Brackets 123, only one of which is shown in the latter figures, aresuitably secured to he corresponding side frame members Ma, 3112. One ofthe movable brackets I21 has the inner end of a link I25 (H68. 14 and15) pivotally connected thereto. The other end of link 125 is pivotallyconnected to a follower am 126 which extends forwardly adjacent theouter surface of frame member 3th and is pivotally connected, as at 127(FIG. 14), to side frame member 31b. A medial portion of follower armI26 has a follower 130 thereon which engages the irregular peripheralgroove of a cam wheel 131 fixed on a corresponding cam shaft 132journalled in frame 31. Cam shaft 132 and cam 131 are driven, to rotateone revolution during every two revolutions of main drive shafl 43, bysuitable belt and pulley means 134 connecting drive shaft 43 to cm shaft132, as best shown in FIGS. and 13.

[t is apparent that cam wheel 131 transmits lateral reciprocatory motionto the pile formers 23 through the intervening connections heretoforedescribed, with the walls of the peripheral groove in earn 131 being soshaped as to impart lateral movement to the pile formers in onedirection during alternate cycles in the operation of needles 20, 21 andthread guides 22, and to impart lateral motion to the pile formers inthe opposite direction during intervening cycles in the operation of theneedles 20, 21 and thread guides 22.

As heretofore described, it is preferred that pile formers 23 areprovided with at least two pile forming stages 23a, 23b of relativelydifferent heights so as to form pile tufts of different lengthsaccording to a predetermined pattern by selectively presenting theloop-forming stages or surfaces 23a, 23b to the loop-forming position inalignment with the tufiing needles. Accordingly, it will be observed inFIGS. 16 and 17 that each pile former is biased in a forward directionby a corresponding compression spring 140, and the rear portion of eachpile former 23 has one end of a control cord 142 connected thereto.

Control cords 142 extend rearwardly and then partially around andupwardly from a guide rod 143 whose opposing ends are carried bybrackets 144 suitably secured to and extending rearwardly from sideframe members 31a, 31b. The control cords 142 are connected to andcontrolled by a suitable pattern device 146 shown schematically in FIG.II and which may be in the form of a Jacquard mechanism or dobby head.It is apparent that such pattern device will function to selectivelylifi the control cords 142 so as to pull the respective pile formersrearwardly in opposition to the respective springs and, upon theselected cords being released. the springs 140 will bias thecorresponding pile wires forwardly so that the low pile forming stagesor surfaces 230 thereof will move along the corresponding rows of loopspreviously formed thereon to position the higher loop forming stages 23bthereof in the tuft-forming position. In this regard, although theneedles 20 successively insert the lower bight portions 26b of each rowof pile tufls at substantially longitudinally aligned points in thebacking fabric 24, it will be observed in FIG. 1, for example, that thelower surfaces of the pile formers are spaced sufl'iciently above thebacking fabric to permit the front ends of the lower stages 23a of thepile formers 23 to enter a few of the loops positioned forwardly thereofwhen the pattern device 146 calls for corresponding relatively highloop-forming stages 23b to be moved into operative position relative totutting needles 20.

It is thus seen that we have provided means for controlling andoperating the tuft-forming instrumentalities of this invention in themanner earlier described. It should be noted, that by controlling thetension in the pile yarns 26, as by varying the size of the weightmembers 53 (FIG. 11), the upper surfaces of the lower bight portions ofthe tuhs 26a may occupy any predetermined position above the lower faceof backing fabric 24, or the lower bight portions 26: may be positionedentirely above the upper face of backing fabric 24.

In the drawings and specification, there has been set forth a preferredembodiment of the invention, and although specific terms are employed,they are used in a generic and descriptive sense only and not forpurposes of limitation.

We claim:

1. In a tufting machine having reciprocating tufting needles forrepeatedly penetrating a backing fabric from one face thereof to insertrespective bight portions of loops of pile yarns therethrough; thecombination therewith of reciprocating latch needles adjacent theopposite face of the backing fabric and extending generally transverselyof the tufting needles, means for moving said latch needles to causethem to enter through and withdraw from the respective pile yarn bightportions presented by said tulting needles, means providing anindependent source of supply of locking threads for said latch needles,and means operatively associated with said latch needles for guiding alocking thread from the source of supply thereof laterally across andinto the hook of each latch needle whenever it has entered through apile yarn bight portion such that each latch needle draws a loop oflocking thread through each respective pile yarn bight portion thuspresented during each withdrawal of said latch needles.

2. A tufiing machine according to claim 1, including means for movingthe backing fabric along a path above said latch needles in timedrelation to reciprocation of said tufting needles and said latchneedles, each latch needle including a shank on which the respectivelatch is pivotally suspended, the hook of each latch needle facingdownwardly, said guiding means being operable to guide each respectivelocking thread, extending from a previously formed lower bight portionof pile yarn, partially around a subsequently presented pile yarn bightponion and into the respective open hook, and the thus presented pileyarn bight portion serving to close the respective latch duringsubsequent withdrawal of the latch needles to prevent the presented pileyarn bight portions from becoming ensnared in the hooks of the latchneedles during withdrawal of said latch needles.

3. A tufting machine according to claim 1, including means for movingthe backing fabric in one longitudinal direction in timed relation tothe operation of said needles, a plurality of pile formers adjacent therespective tufting needles, and

means for effecting relative lateral movement between said tuftingneedles and said pile formers in timed relation to reciprocation of saidtufting needles such that the pile yarns are looped across correspondingpile formers when said tufting needles are withdrawn from the backingfabric.

4. A tufting machine according to claim 3, wherein said means foreffecting relative lateral movement between said tufting needles andsaid pile formers comprises means to shift each pile former in onelateral direction during each alternate period in which said tuftingneedles are withdrawn and to shift each pile former in the oppositelateral direction during each intervening period in which said tuftingneedles are withdrawn.

5. A tufting machine according to claim 3, wherein each of at least someof said pile formers includes pile forming surfaces of different heightsthereon, and means connected to said some of said pile formers forselectively presenting different height surfaces thereof to said tuftingneedles.

6. A tufting machine according to claim 3, wherein the pile yarns extendfrom a source through said tufting needles to the backing fabric, andmeans engaging the pile yarns between their source and said needles andpreventing slackening of the pile yarns during movement of the tufiingneedles so that the tufting needles retract previously formed pile yarnbight portions into the backing fabric as the tuiting needles penetratethe backing fabric and pull the pile yarns over adjacent pile formerswhile the tufting needles form succeeding pile yarn bight portionsadjacent said opposite face of the backing fabric.

7. A tufting machine according to claim 1, including pile formersadjacent said one face of the backing fabric and over which said loopsare formed by said tufting needles, and means for moving said tuftingneedles in timed relation to said latch needles so that, during theinsertion of a succeeding pile yarn bight portion by each tuftingneedle, the respective latch needle is withdrawn from and will havereleased an immediately preceding pile yarn bight portion therefrom asthe preceding pile yam bight portion is thus pulled toward the backingfabric by the tufting needle pulling the respective pile yarn over thepile former and into the backing fabric in the forming of the succeedingloop.

8. [n a tutting machine having means for advancing a backing fabriclengthwise thercthrough, and tufting needles for forming loop pile tuftsfrom pile yarns on one face of the backing fabric by repeatedlyinserting pile yarn bight portions of the tufts through to the oppositeface of the backing fabric; the combination therewith of means forinserting locking threads through successive pile yarn bight portions asthey are inserted through the backing fabric for securing the loop piletufts to the backing fabric, a plurality of pile formers extendinglengthwise of and adjacent said one face of the backing fabric and overwhich said loop pile tufts are formed by said tufting needles, at leastsome of said pile formers each including loop-forming surfaces ofdifferent heights thereon, and means for selectively moving said some ofsaid pile formers longitudinally to present the different heightsurfaces thereof to said tufting needles and to form loop pile tuftsthereover of corresponding different heights.

9. A tufling machine according to claim 8, wherein said means forinserting locking threads through successive pile yarn bight portionscomprises a reciprocating latch needle for each tufling needle andpositioned adjacent the opposite face of the backing fabric forinserting through and withdrawing from the pile yarn bight portionspresented by the tufting needles, an independent source of supply forthe locking threads, and means operatively associated with said latchneedles for guiding a locking thread from the independent source ofsupply laterally across and into the hook of each latch needle wheneverit has entered through a pile yarn bight portion whereby each latchneedle draws a loop of locking thread through each respective pile yarnbight portion thus presented during each withdrawalpf said latchneedles.

10. A tufttng machine according to claim 9, including means for movingsaid tufting needles and said latch needles in such timed relationshipthat, during the insertion of a succeeding pile yarn bight portion byeach tufting needle, the respective latch needle is withdrawn from andwill have released an immediately preceding pile yarn bight portiontherefrom and the preceding bight portion is thus pulled toward thebacking fabric by the tufiing needle pulling the respective pile yarnover the pile former and into the backing fabric in the forming of thesucceeding loop pile tuft.

i l B I i UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PatentNo. 3, 677,206 Dated July 18, 1972 Inventor(s) J. T. MacIsaac and J. E.Troy It: is certified that error appears in the above-identified patentand that said Letters Patent are hereby corrected as shown below:

Column 1, line 49, after "100p" insert ---of-, same column, line 59,after "are" insert -views. Column 2, line 52, after "latch" insertneed1es--; same column, line 67, after "26" insert -is-. Column 3,

line 44, "needle 29" should bev --needle 20-- Signed and sealed this 2ndday of January 1973.

(SEAL) Attest:

EDWARD M. FLETCHER,JR. ROBERT GOTTSCHALK Attesting Officer Commissionerof Patents OHM po'wsn uscouwoc scan-P09 U... GOVIIH ICNT PIIIIHIIGDFIICI llll O!ll-J34

1. In a tufting machine having reciprocating tufting needles forrepeatedly penetrating a backing fabric from one face thereof to insertrespective bight portions of loops of pile yarns therethrough; thecombination therewith of reciprocating latch needles adjacent theopposite face of the backing fabric and extending generally transverselyof the tufting needles, means for moving said latch needles to causethem to enter through and withdraw from the respective pile yarn bightportions presented by said tufting needles, means providing anindependent source of supply of locking threads for said latch needles,and means operatively associated with said latch needles for guiding alocking thread from the source of supply thereof laterally across andinto the hook of each latch needle whenever it has entered through apile yarn bight portion such that each latch needle draws a loop oflocking thread through each respective pile yarn bight portion thuspresented during each withdrawal of said latch needles.
 2. A tuftingmachine according to claim 1, including means for moving the backingfabric along a path above said latch needles in timed relation toreciprocation of said tufting needles and said latch needles, each latchneedle including a shank on which the respective latch is pivotallysuspended, the hook of each latch needle facing downwardly, said guidingmeans being operable to guide each respective locking thread, extendingfrom a previously formed lower bight portion of pile yarn, partiallyaround a subsequently presented pile yarn bighT portion and into therespective open hook, and the thus presented pile yarn bight portionserving to close the respective latch during subsequent withdrawal ofthe latch needles to prevent the presented pile yarn bight portions frombecoming ensnared in the hooks of the latch needles during withdrawal ofsaid latch needles.
 3. A tufting machine according to claim 1, includingmeans for moving the backing fabric in one longitudinal direction intimed relation to the operation of said needles, a plurality of pileformers adjacent the respective tufting needles, and means for effectingrelative lateral movement between said tufting needles and said pileformers in timed relation to reciprocation of said tufting needles suchthat the pile yarns are looped across corresponding pile formers whensaid tufting needles are withdrawn from the backing fabric.
 4. A tuftingmachine according to claim 3, wherein said means for effecting relativelateral movement between said tufting needles and said pile formerscomprises means to shift each pile former in one lateral directionduring each alternate period in which said tufting needles are withdrawnand to shift each pile former in the opposite lateral direction duringeach intervening period in which said tufting needles are withdrawn. 5.A tufting machine according to claim 3, wherein each of at least some ofsaid pile formers includes pile forming surfaces of different heightsthereon, and means connected to said some of said pile formers forselectively presenting different height surfaces thereof to said tuftingneedles.
 6. A tufting machine according to claim 3, wherein the pileyarns extend from a source through said tufting needles to the backingfabric, and means engaging the pile yarns between their source and saidneedles and preventing slackening of the pile yarns during movement ofthe tufting needles so that the tufting needles retract previouslyformed pile yarn bight portions into the backing fabric as the tuftingneedles penetrate the backing fabric and pull the pile yarns overadjacent pile formers while the tufting needles form succeeding pileyarn bight portions adjacent said opposite face of the backing fabric.7. A tufting machine according to claim 1, including pile formersadjacent said one face of the backing fabric and over which said loopsare formed by said tufting needles, and means for moving said tuftingneedles in timed relation to said latch needles so that, during theinsertion of a succeeding pile yarn bight portion by each tuftingneedle, the respective latch needle is withdrawn from and will havereleased an immediately preceding pile yarn bight portion therefrom asthe preceding pile yarn bight portion is thus pulled toward the backingfabric by the tufting needle pulling the respective pile yarn over thepile former and into the backing fabric in the forming of the succeedingloop.
 8. In a tufting machine having means for advancing a backingfabric lengthwise therethrough, and tufting needles for forming looppile tufts from pile yarns on one face of the backing fabric byrepeatedly inserting pile yarn bight portions of the tufts through tothe opposite face of the backing fabric; the combination therewith ofmeans for inserting locking threads through successive pile yarn bightportions as they are inserted through the backing fabric for securingthe loop pile tufts to the backing fabric, a plurality of pile formersextending lengthwise of and adjacent said one face of the backing fabricand over which said loop pile tufts are formed by said tufting needles,at least some of said pile formers each including loop-forming surfacesof different heights thereon, and means for selectively moving said someof said pile formers longitudinally to present the different heightsurfaces thereof to said tufting needles and to form loop pile tuftsthereover of corresponding different heights.
 9. A tufting machineaccording to claim 8, wherein said means for inserting locking threadsthrough successive pile yarn bight portions comprises a reciprocatinglatch needle for each tufting needle and positioned adjacent theopposite face of the backing fabric for inserting through andwithdrawing from the pile yarn bight portions presented by the tuftingneedles, an independent source of supply for the locking threads, andmeans operatively associated with said latch needles for guiding alocking thread from the independent source of supply laterally acrossand into the hook of each latch needle whenever it has entered through apile yarn bight portion whereby each latch needle draws a loop oflocking thread through each respective pile yarn bight portion thuspresented during each withdrawal of said latch needles.
 10. A tuftingmachine according to claim 9, including means for moving said tuftingneedles and said latch needles in such timed relationship that, duringthe insertion of a succeeding pile yarn bight portion by each tuftingneedle, the respective latch needle is withdrawn from and will havereleased an immediately preceding pile yarn bight portion therefrom andthe preceding bight portion is thus pulled toward the backing fabric bythe tufting needle pulling the respective pile yarn over the pile formerand into the backing fabric in the forming of the succeeding loop piletuft.